Vehicle mirror having polymeric reflective film element and self-dimming element

ABSTRACT

A rearview mirror assembly comprises a reflective element, preferably fabricated of a lightweight, rigid, high-strength plastic and a relatively thin reflective film conformably attached thereto. A portion of the reflective element can also comprise a convex surface for monitoring the “blind spot” typically experienced by the driver. A mirror-mounted light assembly, such as for turn signals, can be incorporated into the reflective element. The mirror assembly can also comprise a chromomorphic polymeric element in planar alignment with the reflective element, which can be electrically and/or thermally activated. The chromomorphic polymeric element can change its resident color between transparent and a predetermined activated color to provide a dimming function as a characteristic of the particular chromomorphic polymeric element that is employed.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. provisional application Ser.No. 60/319,199, filed Apr. 23, 2002, and 60/319,218, filed May 1, 2002,which are incorporated herein in their entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a rearview mirror for an automotive vehicle. Inone aspect, the invention relates to a one-piece mirror element for arearview mirror. In another aspect, the invention relates to a one-piecemirror element having an integral convex portion. In another aspect, therearview mirror has an automatic dimming feature performed by achromomorphic polymer.

2. Description of the Related Art

Side-mounted rearview mirrors for automotive vehicles typically comprisea multi-piece (and multi-layer) mirror element. The mirror element willgenerally comprise a mounting panel or “glass case” to which areflective element is attached. The glass case can be fabricated of arigid, high-strength plastic or a metal such as steel. A reflectiveelement, i.e. the mirror, is fixedly attached to the glass case with anadhesive or a mechanical hold-down assembly. The reflective elementtypically comprises a piece of glass with a reflective coating on oneside, similar to a conventional household mirror. A heating element canalso be attached to the glass case for defogging or deicing thereflective element. The mirror element is housed within a mirror housingwhich is attached to the side of the vehicle. A glass or rigid,impact-resistant clear plastic plate may be attached to the mirrorhousing to enclose the mirror element and protect it from impact or theweather. A bezel may also be placed over the reflective element tosecure the reflective element to the mounting panel, add furtherprotection to the reflective element and/or people adjacent to thevehicle, and improve the appearance of the mirror element.

Manufacture of multi-piece mirror elements involves several separatefabrication and assembly steps, and the complicated fabrication andassembly process can be expensive. Having a mirror with multiple piecesincreases the likelihood that one piece may fail or be damaged, therebyincreasing the risk that costly repairs or replacement will benecessary. Furthermore, the differential shrinkage rates between themounting plate and the glass require a design “gap” between theseelements to avoid cold weather creating excessive side pressure and hoopstress that may distort and ultimately crack the glass element.

The various components making up the mirror element can be relativelyheavy, particularly where several pieces of glass are used. Inparticular, mms used for trucks, SUVs, and other large vehicles can bequite large and heavy. Heavier mirrors require stronger supporting andmounting components, more robust adjustment actuators, and cancontribute to a reduction in the mileage of the vehicle due to theweight of the mirror. Heating elements for defogging or defrosting themirror must be larger and will consume more energy due to the higherheat capacity of the heavy, multi-piece mirror element.

The use of a plastic mounting panel can give rise to structuralimperfections such as “read-through” and waviness which can, in turn,introduce unacceptable optical imperfections in the mirror element.“Read-through” refers to the ability to see underlying geometry on anouter opaque surface due to localized shrink and deformation. Thislocalized shrink and deformation occurs more readily in relatively thicksections of the material. Surfaces with high curvature hide these flaws,but they can be quite noticeable on flat surfaces. With plastics, forexample, integral supporting ribs traversing one side of a panel can beseen as a corresponding image on the opposite side of the panel. If thereflective element is a film, this “read-through” image can be seen inthe film, distorting the reflection image.

Similarly, deviations from a plane surface, or “waviness,” in theplastic mounting panel can give rise to a non-planar reflective surface,particularly where a reflective film is used, thereby distorting thereflection image.

Rearview mirrors can be provided with a convex mirror for eliminatingthe “blind zone” experienced by the driver. This generally comprises aseparate glass or plastic component, further increasing the fabricationcosts and weight of the mirror assembly. Rearview mirrors can also beprovided with small light assemblies, such as for turn signals, whichare typically mounted to shine through the glass comprising thereflective element. Locating the lights behind the glass will reduce theintensity of the lights due to transmission losses as the light shinesthrough the glass. To compensate, larger, heavier lights having anincreased power consumption are necessary.

It has also become common to incorporate an automatic-dimming featureinto a rearview mirror, whether provided in an interiorwindshield-mounted rearview mirror or an exterior vehicular mirror.These so-called automatic-dimming mirrors typically reduce the intensityof transmitted images thereon in order to reduce the glare encounteredby a driver of the vehicle, typically during nighttime drivingconditions. In order to accomplish this glare-reduction function, anelectrochromic mirror element is provided in the rearview mirror whichtypically comprises a “gel” suspended between a pair of dielectric glassplates which, when the gel is electrified, turn the gel a particularcolor through an oxidation-reduction reaction, thus filtering out anyintense light emitted from the rearview mirror. The mirror is typicallyinterconnected to a controller unit which controls the electrificationof the gel between the glass plates, thus providing the “automatic”dimming of the rearview mirror element.

These types of electrochromic mirror elements are typically expensive tomanufacture and install. In addition, the gel must be sealed within theglass plates, causing additional expense and repair if the seal failsduring use. Further, the glass plates can provide an undesirable amountof weight to a typical rearview mirror assembly since they require apair of glass plates as well as the remainder of the electrochromicelement. Finally, the electrochromic gel is caustic, can be dangerous tohandle during manufacture, and users risk exposure to the electrochromicmaterial as a result of its corrosive nature.

SUMMARY OF THE INVENTION

In one aspect, the invention relates to a vehicular mirror systemcomprising: a vehicular mirror assembly adapted to be mounted to avehicle, the vehicular mirror assembly having a reflective elementmounted therein and a mounting plate for mounting the reflective elementin the vehicular mirror assembly; and said vehicular mirror assemblycomprising a chromomorphic polymer-element mounted to the housing and inregister with the reflective element, wherein the chromomorphic polymerelement is generally transparent in a first state and a translucentcolor in a second state. Activation of the chromomorphic polymer elementthereby performs a dimming function for the reflective element when thechromomorphic polymer element is changed to the second state from thefirst state.

Various embodiments of the invention are also contemplated. For example,the chromomorphic polymer element can be electrically activated. Acontroller can be provided for controlling the operation of thechromomorphic polymer element. The chromomorphic polymer element can beelectrically connected to the vehicle's electrical power supply. Thechromomorphic polymer element can be activated by an electrical currentdelivered to the chromomorphic polymer element. The chromomorphicpolymer element can be thermally activated. A heating element can beprovided in register with the chromomorphic polymer element. The heatingelement can be electrically connected to the vehicle's electrical powersupply. The heating element can be heated by an electrical currentdelivered to the heating element. The chromomorphic polymer element canbe activated by the heating of the heating element. The heating elementcan comprise a heat-generating plastic. The mounting plate can befabricated of the heat-generating plastic. A transparent element can beprovided in register with the chromomorphic polymer element forprotection of the chromomorphic polymer element from weather and impactforces.

In another aspect of the invention, the invention relates to a vehicularmirror system comprising: a vehicular mirror assembly adapted to bemounted to a vehicle, the vehicular mirror assembly having a reflectiveelement mounted therein; a mounting plate for mounting the reflectiveelement in the vehicular mirror assembly and comprising an obverse sideand a reverse side; and the reflective element comprising a polymericreflective film conformably attached to the mounting plate to provide areflection image therein. The reflection image is thereby essentiallyfree of visible distortion.

Various other embodiments of the invention are also contemplated. Forexample, the polymeric reflective film can be attached to the obverseside of the mounting plate. The polymeric reflective film can beattached to the reverse side of the mounting plate. The mounting platecan comprise a planar surface having minimal imperfections to providethe reflection image that is essentially free of visible distortion. Themounting plate can be fabricated of a plastic. The plastic can befabricated by a gas-injection process to provide a core having agenerally uniform distribution of microscopic voids.

A supplemental reflective surface can be provided on the reflectiveelement. The supplemental reflective surface can comprise a circular,convex surface to provide a “fish-eye” view. A single piece of thepolymeric reflective film can form the reflective element and thesupplemental reflective surface.

A plurality of lighting elements can extend through the mounting plateto provide light reflected from the reflective surface. The lightingelements can be positioned along the periphery of the supplementalreflective surface. The lighting elements can be light-emitting diodes.A plurality of lighting elements can extend through the mounting plateto provide light through the reflective film.

A heating element can be provided in register with the reflectiveelement for defogging and defrosting the reflective element. The heatingelement can be a heat-generating plastic. The mounting plate can befabricated from the heat-generating plastic.

In yet an additional aspect, the invention relates to a vehicular mirrorsystem comprising: a vehicular mirror assembly adapted to be mounted toa vehicle, the vehicular mirror assembly having a reflective elementmounted therein; a mounting plate for mounting the reflective element inthe vehicular mirror assembly; the reflective element comprising apolymeric reflective film conformably attached to the mounting plate toprovide a reflection image therein; and a chromomorphic polymer elementmounted to the housing and in register with the reflective element,wherein the chromomorphic polymer element is generally transparent in afirst state and a translucent color in a second state; wherebyactivation of the chromomorphic polymer element performs a dimmingfunction for the reflective element when the chromomorphic polymerelement is changed to the second state from the first state, and whereinthe reflection image is essentially free of visible distortion.

Various embodiments of the invention are also contemplated. For example,the chromomorphic polymer element can be electrically activated. Acontroller can be provided for controlling the operation of thechromomorphic polymer element. The chromomorphic polymer element can beelectrically connected to the vehicle's electrical power supply. Thechromomorphic polymer element can be activated by an electrical currentdelivered to the chromomorphic polymer element. The chromomorphicpolymer element can be thermally activated. A controller can be providedfor controlling the operation of the chromomorphic polymer element. Aheating element can be provided in register with the chromomorphicpolymer element. The heating element can be electrically connected tothe vehicle's electrical power supply. The heating element can be heatedby an electrical current delivered to the heating element. Thechromomorphic polymer element can be activated by the heating of theheating element. The heating element can comprise a heat-generatingplastic. The mounting plate can be fabricated of the heat-generatingplastic.

A transparent element can be provided in register with the chromomorphicpolymer element for protection of the chromomorphic polymer element fromweather and impact forces. The polymeric reflective film can be attachedto the obverse side of the mounting plate. The polymeric reflective filmcan be attached to the reverse side of the mounting plate. The mountingplate can comprise a planar surface having minimal imperfections toprovide the reflection image that is essentially free of visibledistortion. The mounting plate can be fabricated of a plastic. Theplastic can be fabricated by a gas-injection process to provide a corehaving a generally uniform distribution of microscopic voids.

A supplemental reflective surface can be provided in the reflectiveelement The supplemental reflective surface can comprise a circular,convex surface to provide a “fish-eye” view. A single piece of thepolymeric reflective film can form the reflective element and thesupplemental reflective surface. A plurality of lighting elements canextend through the mounting plate to provide light reflected from thereflective surface. The lighting elements can be positioned along theperiphery of the supplemental reflective surface. The lighting elementscan be light emitting diodes. A plurality of lighting elements canextend through the mounting plate to provide light through thereflective film. A heating element in register with the reflectiveelement for defogging and defrosting the reflective element. The heatingelement can be a heat-generating plastic. The mounting plate can befabricated from the heat-generating plastic.

In another aspect, the invention relates to a vehicular mirror systemcomprising: a vehicular mirror assembly adapted to be mounted to avehicle, the vehicular mirror assembly having a first reflective elementand a second blind zone reflective element mounted therein; wherein thesecond blind zone reflective element comprises a polymeric reflectivefilm to provide a reflection image therein.

Various embodiments of the invention are also contemplated. The secondblind zone reflective element can further comprise a supplementalreflective surface formed on a mounting plate configured in a circular,convex surface to provide a “fish-eye” view. The first reflectiveelement can further comprise a polymeric reflective film. A single pieceof the polymeric reflective film can form both the first and secondreflective elements.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a perspective view of a first embodiment of a rearview mirrorassembly according to the invention.

FIG. 2 is a an exploded view of the rearview mirror assembly of FIG. 1showing a mirror element according to the invention, an actuator, and ahousing assembly.

FIG. 3 is a rear elevational view of the mirror element of FIG. 2.

FIG. 4 is a front elevational view of the mirror element of FIG. 2.

FIG. 5 is a cross-sectional view of the mirror element taken along line5-5 of FIG. 3.

FIG. 6 is an exploded view of the mirror element of FIG. 2 showing theaddition of a bezel to the mirror element.

FIG. 7 is an exploded view from the rear of the mirror element of FIG. 2having an integral lighting element comprising a second embodiment ofthe invention.

FIG. 8 is a front elevational view of the mirror element of FIG. 7.

FIG. 9 is a partial sectional view of the mirror element taken alongline 9-9 of FIG. 8 showing the integral lighting element.

FIG. 9A is a close-up view of a portion of the integral lighting elementof FIG. 9.

FIG. 10 is an exploded, perspective view of a third embodiment of therearview mirror assembly of FIG. 1.

FIG. 11 is an exploded, perspective view of the rearview mirror assemblyof FIG. 10 taken from an orientation opposite to that shown in FIG. 10showing non-visible surfaces of the rearview mirror assembly withcomponents of a housing for the rearview mirror assembly removed forpurposes of clarity.

FIG. 12 is a front, elevational view of the rearview mirror assembly ofFIG. 11.

FIG. 13 is a cross-sectional view taken along lines 13-13 of FIG. 12.

FIG. 14 is an exploded, perspective view of a fourth embodiment of therearview mirror assembly of FIG. 1 comprising a thermally-activated,chromomorphic polymeric element associated with a reflective mirrorelement, taken from an orientation of a visible surface of the rearviewmirror assembly.

FIG. 15 is an exploded, perspective view of the rearview mirror assemblyof FIG. 14 taken from an orientation opposite to that shown in FIG. 14showing non-visible surfaces of the rearview mirror assembly withcomponents of a housing for the rearview mirror assembly removed forpurposes of clarity.

FIG. 16 is a front, elevational view of the rearview mirror assembly ofFIG. 14.

FIG. 17 is a cross-sectional view taken along lines 17-17 of FIG. 16.

FIG. 18 is an exploded, perspective view of a fifth embodiment of therearview mirror assembly of FIG. 1 comprising an electrically activated,color changing polymeric element associated with a reflective mirrorelement, taken from an orientation of a visible surface of the rearviewmirror assembly.

FIG. 19 is an exploded, perspective view of the rearview mirror assemblyof FIG. 18 taken from an orientation opposite to that shown in FIG. 18showing non-visible surfaces of the rearview mirror assembly withcomponents of a housing for the rearview mirror assembly removed forpurposes of clarity.

FIG. 20 is a front, elevational view of the rearview mirror assembly ofFIG. 18.

FIG. 21 is a cross-sectional view taken along lines 21-21 of FIG. 20.

FIG. 22 is an exploded, perspective view a sixth embodiment of therearview mirror assembly of FIG. 1 comprising a thermally-activated,chromomorphic polymeric element associated with a reflective mirrorelement taken from an orientation of a visible surface of the rearviewmirror assembly.

FIG. 23 is an exploded, perspective view of the rearview mirror assemblyof FIG. 22 taken from an orientation opposite to that shown in FIG. 22showing non-visible surfaces of the rearview mirror assembly withcomponents of a housing for the rearview mirror assembly removed forpurposes of clarity.

FIG. 24 is a front, elevational view of the rearview mirror assembly ofFIG. 22.

FIG. 25 is a cross-sectional view taken along lines 25-25 of FIG. 24.

FIG. 26 is an exploded, perspective view of a seventh embodiment of therearview mirror assembly of FIG. 1 an electrically activated, colorchanging polymeric element associated with a reflective mirror element,taken from an orientation of a visible surface of the rearview mirrorassembly.

FIG. 27 is an exploded, perspective view of the rearview mirror assemblyof FIG. 26 taken from an orientation opposite to that shown in FIG. 26showing non-visible surfaces of the rearview mirror assembly withcomponents of a housing for the rearview mirror assembly removed forpurposes of clarity.

FIG. 28 is a front, elevational view of the rearview mirror assembly ofFIG. 26.

FIG. 29 is a cross-sectional view taken along lines 29-29 of FIG. 28.

FIG. 30 is an exploded, perspective view of an eighth embodiment of therearview mirror assembly of FIG. 1 comprising a thermally-activated,chromomorphic polymeric element associated with a reflective mirrorelement, taken from an orientation of a visible surface of the rearviewmirror assembly.

FIG. 31 is an exploded, perspective view of the rearview mirror assemblyof FIG. 30 taken from an orientation opposite to that shown in FIG. 30showing non-visible surfaces of the rearview mirror assembly withcomponents of a housing for the rearview mirror assembly removed forpurposes of clarity.

FIG. 32 is a front, elevational view of the rearview mirror assembly ofFIG. 30.

FIG. 33 is a cross-sectional view taken along lines 33-33 of FIG. 32.

DESCRIPTION OF THE PREFERRED EMBODIMENT

A coated plate mirror assembly 10 according to a first embodiment of theinvention is shown in FIGS. 1 and 2. The mirror assembly 10 comprises ahousing assembly 12 enclosing a generally conventional mounting bracketassembly 14, a generally conventional adjustment assembly 16 (shown as atilt actuator assembly), a reflective element 18, and a base assembly 20for attaching the mirror assembly 10 to a motor vehicle (not shown). Thehousing assembly 12 is a generally conventional rearview mirror housingassembly for an automotive vehicle. The mounting bracket assembly 14mounts the adjustment assembly 16 which, in turn, mounts the reflectiveelement 18. The adjustment assembly 16 controls the vertical andhorizontal sight adjustment of the reflective element 18. Although asingle adjustment assembly is shown, multiple adjustment assemblies canbe utilized, each adjustment assembly controlling a single specificfunction, such as horizontal axis and vertical axis adjustment. It willalso be understood that the housing assembly 12 can be pivotally orextendably mounted to the base assembly 20 as is known in the art. Theadjustment assembly 16 is preferably interconnected to a user interface,typically located within the vehicle, for performing the adjustment ofthe reflective element 18.

As shown in FIGS. 3-6, the reflective element 18 comprises a mountingplate 30 and a reflective film 32. The mounting plate 30 has an obverseside 34 and a reverse side 36. The reverse side 36 comprises a mountingsurface 38 having a plurality of adjustment sockets 42 and a pivotsocket 44 operably communicating with the adjustment assembly 16. Theobverse side 34 has a mirror surface 40 to which is attached thereflective film 32. The mounting plate 30 is shown in the figures as agenerally flat plate. However, the mounting plate 30 can alternativelyhave an aspheric, hyperbolic, parabolic, or concave profile. A portionof the mirror surface 40 can also comprise a supplemental reflectivesurface, such as a convex surface 46, shown in FIGS. 1-2 and 4-6 as acircular area in the upper outer corner of the reflective element 18.With the reflective film 32 applied, the convex surface 46 provides a“fish-eye” view to the rear of the vehicle to eliminate the “blind spot”experienced by the driver. Alternatively, the mounting plate 30 can bedivided into a plurality of sections having one or more of an aspheric,hyperbolic, parabolic, concave, or convex profile.

The reflective film 32 can also be covered by a bezel 48 (FIG. 6) toprotect the edges of the reflective film 32 and prevent the reflectivefilm 32 from separating from the mounting plate 30, and provide a“finished” appearance to the reflective element 18. It will beunderstood that it is not a limitation as to which side of the mountingplate 30 the reflective film 32 is applied. The film 32 can be appliedto either the obverse or the reverse side of the mounting plate 30without departing from the scope of this invention. Of course, if thereflective film 32 is mounted to the reverse side of the mounting plate30, the mounting plate 30 will be fabricated from a transparentmaterial. The reflective film 32 can be attached to the mounting plate30 in any known manner, and the particular method of attachment shallnot be construed as limiting on the invention.

The reflective film 32 is a thin, flexible, polymer-based film havingreflective properties, such as the multi-layer reflective film disclosedin U.S. Pat. No. 6,352,761, issued Mar. 5, 2002, and assigned to 3MInnovative Properties Co., St. Paul, Minn., which is incorporated hereinby reference. The reflective film 32 is capable of transmitting lighthaving a diffused quality from a light source located on the side of thefilm 32 opposite the reflective surface. The reflective film 32 isattached to the obverse side 34 of the mounting plate 30 using asuitable process to avoid imperfections in the image provided by thereflective element 18, and to conform the film 32 to the convex surface46.

The mounting plate 30 comprises a polymeric material capable of beingfabricated with planar surfaces having minimal surface imperfections,such as “read-through” and waviness, which can manifest themselves intooptical imperfections in the reflection image. A variety of syntheticresin materials, including thermoplastics, can be used to make themounting plate 30. One such preferable material is that formed by thegas-injected MuCell technology owned by Trexel Inc. which virtuallyeliminates the waviness and “read-through” effects while providing avirtually smooth, warp-free surface. A reduction in weight is achievedwith the use of the reflective film 32 and the elimination of several ofthe elements contained in the prior art multi-piece assembly,particularly the glass elements. Further weight reductions are obtainedby the use of the gas-injected technology (such as MuCell) whichproduces a mounting plate 30 with a core having a generally uniformdistribution of microscopic voids or cells (i.e. “bubbles”). Themounting plate 30, therefore, weighs less than if it was made from asolid polymeric member. It is contemplated that weight reductions of asmuch as an additional twenty percent of the overall weight of themounting plate 30 can be achieved.

It will be understood that other molding techniques as well as othersynthetic resin forming techniques and materials can be used withoutdeparting from the scope of this invention. For example, the mountingplate 30 can be made from an extrusion. Further, the mounting componentsfor attaching the mounting plate 30 to the mirror actuator can be madeas separate components and mechanically attached to the mounting plate30.

For mirror defogging and defrosting functions, an electric-poweredheater pad comprising a thin panel having integrated heating elementsand a shape complementary to the shape of the mounting plate can beinserted between the mirror surface 40 of the mounting plate 30 and thereflective film 32. The heater pad can be selectively energized by thevehicle's 12-volt DC power supply and a suitable controller operable bythe vehicle operator.

The mounting plate 30 can also be comprised of a self-regulating,electrically-conductive, heat-generating plastic such as the Step-Heatplastic marketed by High Sierra Technical of Austin, Tex., and capableof being powered and operated by the vehicle's 12-volt DC electricalsystem. Alternatively, a heat-generating layer capable of being poweredand operated by the vehicle's 12-volt DC electrical system can beintroduced into the reflective element 18, such as sandwiched betweenthe mounting plate 30 and the reflective film 32, or attached to thereverse side 36 of the mounting plate 30. The heat-generating layer cancomprise a heat-generating plastic, or a thin layer of metal. Thismaterial will provide the mirror assembly 10 with defogging and deicingcapabilities. As an alternative, a clear heater assembly, such as thatshown in commonly-owned PCT Application No. WO 99/40039, published Aug.12, 1999, which is incorporated herein by reference, can be employed toprovide heat to the assembly.

The reflective film 32 is attached to the mounting plate 30 throughgenerally conventional laminating operations, with the film 32 beingstretched during the application process to ensure “optical acceptance”and an accurate reflection image, such as a 1% maximum distortionspecification pursuant to Toyota Engineering Standard TSC3901G. Forexample, a clamp-frame can be used on an injection mold which stretchesthe film in two directions. Alternatively, the injection mold can beprovided with a profile groove so that either when the mold is closed,or when the plastic is injected, the film is stretched. Because of themethod of using a thin flexible film 32, and stretching the film 32across the mounting plate 30, the film 32 can be applied to both theflat, obverse side 34 of the panel 30 and the curved, convex surface 46in a single operation to provide a smooth, unbroken reflective surface.

Alternatively, the reflective element 18 can comprise a conventionalcoated mirror, with the supplemental reflective surface 46 comprising aseparate convex surface attached to the mounting plate 30 and having thereflective film 32 applied only to the supplemental reflective surface46. As well, both the mounting plate 30 and the supplemental reflectivesurface 46 can have the reflective film 32 applied separately to eachpiece, followed by attachment of the supplemental reflective surface 46to the mounting plate 30 to form the finished reflective element 18.

Referring to FIGS. 7-9, a second embodiment of the rearview mirrorassembly is shown comprising a light assembly 70 comprising a pluralityof lighting elements 72 in a frame 74, shown for purposes ofillustration as arranged in a generally semicircular configuration. Thelighting elements 72 are adapted to lie along the circumference of theconvex surface 46, which will highlight and draw the driver's attentionto the convex surface 46. The use of the reflective film 32 provides aplurality of individual reflective surfaces for the lighting elements 72for magnifying the intensity of the light therefrom. These reflectivesurfaces are readily fabricated through the use of the film 32.

The lighting elements 72, such as small light bulbs or light-emittingdiodes, are operably interconnected to the vehicle's 12-volt DCelectrical supply and control systems for selective operation of thelight assembly 70. As an example, the light assembly 70 can beelectrically interconnected with the vehicle's turn signals to indicatethe operation of the turn signals when the driver uses the rearviewmirror. In the preferred embodiment, a plurality of lighting elementapertures 76 is provided along a portion of the circumference of theconvex surface 46. As shown in FIGS. 9 and 9A, each lighting elementaperture 76 comprises a cylindrical portion 78 and a conical portion 80.When the reflective film 32 is applied to the mounting plate 30, thereflective film 32 will be drawn into and assume the profile of theconical portion 80.

As shown in FIGS. 7 and 9, the light assembly 70 is attached to themounting plate 30 from the reverse side 36 with the lighting elements 72inserted into the lighting element apertures 76. Because of thereflective film 32, the conical portion 80 comprises a conicalreflective surface, thereby concentrating and magnifying the light fromthe lighting elements 72. The light will also be projected from thereflective element 18, thereby increasing the visibility of the lightingelements 72.

Alternatively, the reflective film 32 can be attached to the mountingplate 30 so that the reflective film 32 bridges over the lightingelement aperture 76 so that the lighting elements 72 are positionedbehind the reflective film 32. Because the reflective film 32 is capableof transmitting light having a diffused quality, the image observedthrough the film 32 will be muted.

The unique one-piece vehicle mirror with a polymeric reflective filmelement comprises fewer components than a conventional multi-piecemirror assembly, is lighter weight, and can be fabricated and assembledwith fewer components and fewer steps, thereby saving costs andcontributing to the improved gas mileage of the automotive vehicle ofwhich it is a part. The use of a single reflective film element enablesthe use of a mounting panel which is lighter and potentially thinner,thereby enabling the use of thinner strengthening and supportingelements. This feature, along with the use of a thermoplastic foam-typepolymer, reduces “read-through” and planar imperfections which candistort the reflection image. The use of a heat-generating plasticeliminates the separate heating element required for a conventionalmulti-piece mirror assembly. An integrated convex “blind spot” elementeliminates the need to fabricate and assemble a separate “blind spot”mirror. The use of the polymeric reflective film element enables the useof the lighting assembly which can be mounted coplanar with or forwardof the reflective surface, thereby eliminating transmission lossesoccurring with lights that are mounted behind glass or plastic panels.

It should also be noted that making the reflective portion (i.e., thefilm 32) and the mounting portion (i.e., the plate 30) out ofcomplementary materials makes the mirror assembly fully recyclablewithout intervening reclamation steps to recover non-recoverablematerials. Also, making the mirror assembly from fully complementarymaterials provides additional benefits in that the shrinkage andexpansion rates due to ambient temperature changes is relatively equalso that distortion in the resultant mirror image is not encountered.

Turning now to FIGS. 10-13, a third embodiment of the mirror assembly 10is shown having several of the previously-described elements andadditionally comprising a mounting plate 114, a first glass element 116,a second glass element 118, and a chromomorphic, i.e. color-changing,polymeric element 120. Thus, like numerals will be used to identify likeelements.

It will be understood that, while a mirror assembly 10 suitable forattachment to an exterior portion of a vehicle, such as in adoor-mounted rear view external mirror, is shown and described herein,the invention is equally applicable to an interior windshield-mountedmirror assembly without departing from the scope of the invention.

As shown in FIGS. 10-13, the mirror assembly 10 preferably comprises amirror housing 122 mounted to a base 124. The mirror assembly 10 canalso include an actuator 126 preferably provided for accomplishingtypical pitch-and-roll adjustment of the mirror components 114-120 as isknown in the a it. The actuator 126 is preferably interconnected to auser interlace, typically located within the vehicle, for performing theadjustment of the mirror components 114-120.

The mounting plate 114 preferably has a forward-facing side 128 and arearward-facing side 130. The forward-facing side 128 preferably hassuitable mounting components 132 for interconnecting the mounting plate114 to the actuator 126 so that adjustments imparted by the actuator 126are transmitted to the mounting plate 114 by the mounting components 132to accomplish the pitch-and-roll adjustment of the mirror components114-120. The mounting components 132 are interconnected to the actuator126 in a known manner and, thus, further description of the interactionbetween the mounting components 132 of the mounting plate 114 and theactuator 126 is not necessary. The rearward-facing side 130 can have abezel 134 (FIG. 13) thereon provided around the periphery of themounting plate 114 and generally extending in a rearward direction toprovide protection to the mirror components 114-120 as assembled.

The first and second glass elements 116, 118 are generally transparentbodies, preferably made of glass, and have a periphery generallycorresponding to that of the mounting plate 114 and generally sized tofit within the periphery of the bezel 134 (if provided on therearwardly-facing side 130 of the mounting plate 114). One of the firstand second glass elements 116, 118, preferably the inner surface of thesecond glass element 118, is provided with a reflective coating thereon,such as the reflective film 32 described previously herein, to providethe rear reflective function of the mirror assembly 10.

The chromomorphic polymeric element 120 is preferably made from amaterial that is generally transparent in a first, non-activated stateand that turns a generally translucent, preferably darkened, color whencatalyzed into a second, activated state. Examples of chromomorphicpolymeric materials are shown in U.S. Pat. Nos. 5,501,945, 6,165,234 and6,286,423 all of which are incorporated herein by reference. Theparticular chromomorphic polymeric material used in the polymericelement 120 is not critical to the invention and many chromomorphicpolymers known in the art are entirely suitable for use as the polymericelement 120 in the inventive mirror assembly 10 described herein. Oneexample of a suitable chromorphic material is a thermochromic (i.e.changing color with changes in temperature) dye manufactured by ColorChange Corporation of Streamwood, Ill.

The polymeric element 120 shown in FIGS. 10-13 is preferably anelectrically activated, chromomorphic polymer. First and secondterminals 136, 138 are electrically interconnected to first and secondterminals 140, 142 comprising a pair of tab-like extensions of thepolymeric element 120 on opposite ends thereof. Opposite end portions ofthe first and second terminals 136, 138 (shown generally by referencenumeral 144) are preferably connected to a suitable on-board vehiclecontroller (not shown), such as a programmable microprocessor, whichprovides appropriate signals through the first and second terminals 136,138 to oscillate the polymeric element 120 between the first,transparent state and the second, darkened state as required by theoperating conditions of the vehicle.

As contemplated by this invention, the first and second terminals 136,138 are preferably maintained in an uncharged state, thus delivering nocurrent to the polymeric element 120 (via the first and second terminals140, 142). Once a chromomorphic (or, i.e., an automatic dimming) featureis required or requested by the controller, the controller deliverscurrent to the first and second terminals 136, 138 via its connections144 to the first and second terminals 140, 142 on the polymeric element120. This delivery of current preferably oscillates the polymericelement 120 to the second, darkened state, causing the chromomorphicpolymer making up the polymeric element 120 to darken to itstranslucent, colored hue. As would be apparent to one skilled in theart, removal of the current through the first and second terminals 136,138, and therefore to the terminals 140, 142, returns the chromomorphicpolymer to its first, transparent state.

The mirror assembly 10 is assembled in generally conventional manner.The actuator 126 is mounted within the mirror housing 122 and isinterconnected to the mounting portions 132 on the forward-facing side128 of the mounting plate 114. The first and second glass elements 116,118 are preferably formed as a subassembly with the chromomorphicpolymeric element 120 sandwiched therebetween.

The first and second glass elements 116, 118 with the polymeric element120 therebetween are preferably mounted to the rearward-facing side 130of the mounting plate 114 in a known fashion, such as by adhesive orultrasonic welding. As can be seen in FIG. 13, when the first and secondglass elements 116, 118 and the chromomorphic polymeric element 120 aremounted to the rearward-facing side 130 of the mounting plate 114, thepolymeric element 120 is uniquely disposed to provide a dimming functionto the reflective coating, such as provided on the first glass element116. As can be seen, as the polymeric element 120 is shifted between thefirst and second states, the transparent and translucent color,respectively, of the particular states of the polymeric element 120provide appropriate dimming and non-dimming to the mirror assembly 10.

The structure, assembly and operation of the fourth to eighthembodiments of FIGS. 14-33 are very similar to the third embodimentshown in FIGS. 10-13. Therefore, the structural differences between thedifferent embodiments will be identified, but a detailed re-descriptionof each of the fourth to eighth embodiments of FIGS. 14-33 will not beprovided. It will be understood that like elements that are common tothe multiple embodiments of the mirror assembly 10 described herein areidentified with like reference numerals on the drawings, obviating there-description of the elements of the fourth through eighth embodiments.

With reference to FIGS. 14-17, the fourth embodiment of the mirrorhousing 10 is very similar to the third embodiment in FIGS. 10-13 exceptthat the electrically-activated, chromomorphic polymeric element 120 hasbeen replaced with a thermally-activated chromomorphic polymeric element150. The thermally-activated chromomorphic polymeric element 150 islocated between the first and second glass plates 116, 118 as in thethird embodiment of FIGS. 10-13. One additional element is provided inthe fourth embodiment shown in FIGS. 14-17 of the mirror housing 10which can be an optional element for the third embodiment of the mirrorhousing 10. A heater 152, and preferably a clear heater as shown in PCTApplication No. WO 99/40039, published Aug. 12, 1999, which isincorporated herein by reference, is provided to heat the polymericelement 150 in accordance with a suitable, predetermined signal from acontroller.

The heater 152 preferably has first and second terminals 154, 156 whichare interconnected to a controller; as in the third embodiment, viarecesses 158 in the mounting plate 114 to electrically interconnect theheater 152 to the onboard vehicle power supply and to the controller.Thus, activation of the heater 152 heats the first and second glassplates 116, 118, and the polymeric element 150 located therebetween. Asthe polymeric element 150 is raised in temperature, it is moved from itsfirst, transparent state to its second, darkened state, and performs thedimming feature to the first and second glass plates 116, 118 as in thethird embodiment.

The fifth and sixth embodiments of FIGS. 18-21 and 22-25, respectively,are variations on the third and fourth embodiments, respectively. As canbe seen from FIGS. 18-21 and 22-25, the fifth and sixth embodiments area single-glass-pane version of the third and fourth embodiments.Specifically, the fifth and sixth embodiments do not have the secondglass element 118 but, rather, these embodiments have only the firstglass element 116 (preferably with a reflective coating thereon)disposed between the chromomorphic polymeric element and the mountingplate 114.

In the fifth embodiment, the chromomorphic polymeric element is anelectrically activated, chromomorphic polymeric element identified byreference numeral 120. In the sixth embodiment, the chromomorphicpolymeric element is a thermally-activated chromomorphic polymericelement identified by reference numeral 150. It can also be noted that aheater 152 is provided in the sixth embodiment to provide a catalystheat source for the thermally-activated chromomorphic polymeric element150.

It will be understood that, since the polymeric element 120/150 in thefifth and sixth embodiments comprises an exterior surface of the mirrorassembly 10 which is exposed to the elements, the polymeric element120/150 is preferably a sufficient thickness to withstand exposure tothe elements. Alternatively, the polymeric element 120/150 can beprovided with an external coating of a suitable protectant to allow thepolymeric element 120/150 to further withstand exposure to the elements.

The seventh and eighth embodiments of FIGS. 26-29 and 30-33,respectively, are further variations on the third and fourth embodimentsshown in FIGS. 10-13 and 14-17, respectively. As can be seen from FIGS.26-29 and 30-33, the seventh and eighth embodiments the simplifiedmirror assemblies with both glass elements 116, 118 removed. In theseventh and eighth embodiments, the mounting plate 114 has a reflectivefilm 160 mounted directly thereon as previously shown and described withrespect to the reflective film 32—no glass elements are utilized for theseventh and eighth embodiments. In the seventh embodiment, anelectrically activated, chromomorphic polymeric element 120 is providedover the reflective film 160. In the eighth embodiment, athermally-activated, chromomorphic polymeric element 150 is providedover the reflective film 160. As in the previous embodiments, whichrelate to the thermally-activated chromomorphic polymeric element 150, aheater 152 is provided between the chromomorphic polymeric element 150and the reflective film 160 on the mounting plate 114. As we have thefifth and sixth embodiments, the polymeric element 120/150 is preferablya sufficient thickness to withstand exposure to the elements, or isprovided with an external coating of a suitable protectant to allow thepolymeric element 120/150 to withstand exposure to the elements.

Alternatively, the heater 152 can be eliminated by utilizing aheat-generating plastic for the mounting plate 114, such as theStep-Heat plastic marketed by High Sierra Technical of Austin, Tex., aspreviously disclosed herein with respect to the mounting plate 30. Themirror assembly 10 will thus comprise the mounting plate 114, thereflective film 160, and the polymeric element 150. Indeed, in each ofthe previous embodiments disclosed herein utilizing athermally-activated chromomorphic polymeric element 150, the heater 152can be eliminated and the mounting plate 114 fabricated of aheat-generating plastic.

It will be understood that the chromomorphic polymeric elements 120/150described herein can be any suitable chromomorphic polymer of any of anumber of materials and activation types. For example, in addition tothe electrically- and thermally-activated, chromomorphic polymersdescribed herein, the chromomorphic polymers can also be activated bylight (photochromic), chemicals (chemochromic), vibration(piezochromic), water (aquachromic), and the like. For example, if aphotochromic, chromomorphic polymer were used, the need for an on-boardcontroller may be eliminated. If a chemochromic, chromomorphic polymerwere used, the controller can be modified to apply one or more catalystchemicals to oscillate the chromomorphic polymer between its states if apiezochiomic, chromomorphic polymer were used, the mirror assembly 10could be modified to include an appropriate vibratory actuator or,alternatively, the actuator 126 could be modified to include acontrollable vibratory element thereon. As would be apparent to oneskilled in the art, the invention described herein contemplates multipletypes of suitable chromomorphic polymeric elements without departingfrom the scope of this invention and the particular types ofchromomorphic elements described herein should not be construed aslimiting on the invention.

Several other advantages from this invention can be realized from theuse of a polymeric film reflector as opposed to a conventionalglass-and-chrome mirror element.

First, the polymeric film, such as the exemplary embodiment describedherein, has light transmissibility qualities so that a light sourcepositioned adjacent one side of the polymeric reflector will transmitlight through the polymeric reflector through to the other side thereof.This allows a mirror system incorporating the polymeric reflectorelement to include such illumination-based functional componentspositioned within the mirror system behind the polymeric reflector suchas a turn signal, assist light, reverse light, blind zone indicator andthe like without requiring that an aperture be formed in the reflectiveelement as in prior art mirror devices.

Second, the polymeric reflective film as described herein consists ofnonmetallic, polymeric layers and thus is recyclable, and can be putthrough a reclamation process without separation from any attachedmounting components.

Third, the formability and conformability of the polymeric reflectivefilm provide distinct manufacturing advantages in attachment andmounting of the polymeric reflective film to a mirror system. Inaddition, the conformability properties of the film permit the polymericreflective element to be applied to a surface with a radius ofcurvature, such as that used in blind zone mirror applications.

It will also be understood that, while the invention has been describedwith respect to a vehicular rearview mirror, the invention is equallyapplicable to other technology areas where a dimming feature is desired,including architectural glass. For example, a dimming architecturalwindow can be created by simply removing the reflective film on each ofthe six embodiments described herein and mounting a glass pane with achromomorphic polymeric element described herein associated therewith.

While the invention has been specifically described in connection withcertain specific embodiments thereof, it is to be understood that thisis by way of illustration and not of limitation. Reasonable variationand modification are possible within the scope of the foregoingdisclosure and drawings without departing from the scope of theinvention.

1-63. (canceled)
 64. A vehicular rear-view mirror comprising: asubstrate; and a reflective element formed by conforming an allpolymer-based reflective film to said substrate.
 65. The mirror of claim64 wherein said reflective film is capable of transmitting light. 66.The mirror of claim 64 wherein said substrate is fabricated fromheat-generating plastic.
 67. The mirror of claim 65 wherein, when saidsubstrate is electrically powered, heat generated by the heat-generatingplastic performs at least one of a defrosting and a defogging operationon the reflective element.
 68. The mirror of claim 64 wherein saidsubstrate is electrically powered.
 69. The mirror of claim 64 whereinsaid substrate is formed from a polymeric material.
 70. The mirror ofclaim 64 wherein said substrate comprises a planar surface and thereflective element substantially covers the planar surface.
 71. Themirror of claim 69 wherein said planar surface has minimal imperfectionsthereon to provide a reflection image off the reflective element withreduced visible distortion.
 72. The mirror of claim 64 wherein saidsubstrate is fabricated by a gas-injection process to provide a corehaving a generally uniform distribution of microscopic voids.
 73. Themirror of claim 64 wherein said substrate includes a surface extendingfrom the substrate and configured to provide a wide-angle view whencovered by the reflective film.
 74. The mirror of claim 72 wherein saidsurface is generally circular.
 75. The mirror of claim 72 wherein saidsurface is generally convex.
 76. The mirror of claim 64 comprising aheating element for at least one of defogging and defrosting thereflective element.
 77. The mirror of claim 75 wherein said heatingelement comprises a heat-generating plastic.
 78. The mirror of claim 76wherein said substrate is at least partially fabricated ofheat-generating plastic.
 79. The mirror of claim 64 further comprising ablind zone reflective element provided thereon.
 80. The mirror of claim77 wherein said heat-generating plastic generates heat when electricallypowered.
 81. The mirror of claim 79 wherein at least a portion of thereflective element conforms to a generally convex surface formed on thesubstrate configured to provide a wide-angle view.
 82. The mirror ofclaim 64 wherein said reflective film conforms both to a generallyplanar portion of the substrate and a generally convex portion of thesubstrate to provide a generally planar reflection portion and awide-angle reflective portion.
 83. A vehicular rear-view mirrorcomprising: a substrate; a reflective element formed by conforming anall polymer-based reflective film to said substrate; wherein saidsubstrate is formed from a polymeric material; and wherein saidreflective film is capable of transmitting light.
 84. A vehicularrear-view mirror comprising: a substrate; a reflective element formed byconforming an all polymer-based reflective film to said substrate;wherein said reflective film is capable of transmitting light emitted bya light-emitting device, said light emitting device being disposed tothe rear of said reflective element so as to emit light through saidreflective element.